Method for producing a coated component and a coated component

ABSTRACT

A method for producing a coated component is provided comprising providing a base body comprising a fibre-reinforced plastic, and applying a coating of a ceramic material directly to the base body.

FIELD OF THE DISCLOSURE

The present disclosure relates to a method for producing a coated component and to a coated component.

BACKGROUND

Various methods for producing coated components are known. Document DE 93 05 806 U1 relates to a method for producing a printing roller. In this method a coating of copper or of a copper alloy is produced, by means of plasma spraying, on a base body of a thermoplastic fibre-reinforced plastic. In document DE 10 2009 048 709 A1 a further method for producing a composite component of a fibre-reinforced plastic and a metal is described.

While metals and metal alloys can be applied directly to a fibre-reinforced plastic, this is not possible in the case of ceramic materials. When a ceramic material is to be applied to a base body comprising fibre-reinforced plastic, in the state of the art an intermediate coating comprising an adhesive medium is always first formed on the base body. For example zinc is used as an adhesive medium. Thus an additional process step is required for production, and material for the adhesive medium is consumed.

Document U.S. Pat. No. 4,997,704 A discloses a method for applying a ceramic coating to a fibre-reinforced material. Prior to the application of the ceramic material an adhesive intermediate coating is applied to the fibre-reinforced material. Document EP 0 514 640 A1 discloses a method for applying a ceramic coating to a body by means of a thermal spraying process. A base body comprises a synthetic resin coating that comprises a particulate material. The synthetic resin coating is treated before a further coating is applied by means of the thermal spraying process. Document EP 0 273 298 A2 discloses an erosion-resistant coating that adheres to a plastic material by means of a binding agent.

SUMMARY OF THE DISCLOSURE

The present disclosure provides improved technologies for coating components. In particular, a non-corrosive adhesion background for coating is be provided. The present disclosure provides a method for producing a coated component comprising providing a base body comprising a fibre-reinforced plastic, applying a coating of a ceramic material directly to the base body, and retaining a region between the base body and the coating comprising the ceramic material free from an intermediate coating such as an adhesive medium.

According to a further aspect a coated component comprising a base body made of a fibre-reinforced plastic and a coating of a ceramic material that is arranged directly on the base body is formed.

Obviating the need for applying an adhesive medium results in fewer process steps, which renders the method both faster and more economical. Furthermore, the characteristics of the component are improved. Corrosion of the adhesive medium, which corrosion often occurred with prior art, is avoided.

A fibre-reinforced plastic (FRP) (also: fibre-composite plastic structure or fibre-reinforced plastic composite) is a material containing reinforcement fibres that are embedded in a plastic matrix. The matrix encloses the reinforcement fibres that are bound to the matrix by means of adhesive forces or cohesive forces.

The base body can, for example, comprise a glass-fibre-reinforced plastic (GRP). As an alternative, the base body can comprise a carbon-fibre-reinforced plastic (CRP), a fibre-reinforced polyamide (PA) or a fibre-reinforced epoxy resin (EP).

The coating comprising a ceramic material can result in a dielectric strength of the component of up to 40 kV. Furthermore, the coating comprising a ceramic material provides thermal insulation of the base body arranged underneath it. The coating thus provides protection against excessive heat. Moreover, the coating comprising a ceramic material is wear-resistant, very hard, pressure resistant and provides very high coating strength.

The coating comprising a ceramic material can be applied in a single layer or in multiple layers to the base body. Furthermore, it can be provided for the application of several layers comprising different ceramic materials to the base body.

The coating comprising a ceramic material can be applied at a coating thickness of 100 μm to 3 mm. On completion of curing, the coating comprising a ceramic material can comprise an adhesive tensile strength greater than or equal to 10 N/mm² In another embodiment, on completion of curing, the coating comprising a ceramic material can comprise an adhesive tensile strength greater than or equal to 5 N/mm².

It can be intended for the base body to be provided on a substrate. The substrate can comprise a metal, for example aluminium, a metal alloy, for example steel, or a non-metallic material. The substrate can fully comprise one of the above-named materials or classes of material.

It can be provided for the coating comprising a ceramic material to be sprayed onto the base body. In one embodiment, the coating comprising a ceramic material is applied to the base body by means of thermal spraying. In thermal spraying, additives, so-called spraying additives, are melted, melted to, or melted on, inside or outside a spray burner. The additives are accelerated in a gas flow in the form of spray particles, and are applied to the surface of the base body to be coated. The formation of a coating can occur in this process. Suitable thermal spraying processes include, for example, high-velocity oxy-fuel flame spraying (HVOF), vacuum plasma spraying (VPS) and atmospheric plasma spraying (APS). Argon, hydrogen, nitrogen or a combination thereof can be used as a process gas for atmospheric plasma spraying. Furthermore, nitrogen, a nitrogen-argon mixture, an argon-hydrogen mixture or argon can be used as a conveying gas in atmospheric plasma spraying. Cooling can take place by means of compressed air, carbon dioxide (CO2) or a combination Thereof.

According to one embodiment it can be provided for the coating to be a ceramic material comprising an oxide ceramic material, for example titanium dioxide (TiO2), chromium oxide (Cr2O3) or aluminium oxide (Al2O3). As an alternative, the coating can be a ceramic material comprising engineering ceramics or technical ceramics.

It can be provided for the coating of a ceramic material to be applied in powder form to the base body, for example by means of thermal spraying. The powder can have a degree of purity in excess of 95%, preferably of 98% to 99.95%. The powder can be provided in the form of any of the following powder forms: mixed ceramic material, water-atomized ceramic material, gas-atomized ceramic material, encased ceramic material, chemically encased ceramic material, agglomerated ceramic material, agglomerated and sintered ceramic material, agglomerated and hollow-spherical ceramic material, agglomerated and compacted ceramic material, melted and broken ceramic material, melted, broken and mixed ceramic material, and sintered and broken ceramic material. Particles of the powder can comprise the following particle sizes: 10/5 μm, 22/5 μm, 45/16 μm, 25/5 μm, 45/20 μm and 30/10 μm. Particles of the powder can also comprise particle sizes in any combination of the above-mentioned particle sizes. If the powder is applied to the base body by means of thermal spraying, an internal axial powder supply, an internal radial powder supply or an external powder supply can take place.

As an alternative, the coating comprising a ceramic material can be applied in the form of a suspension, for example as a water-based suspension or as an alcohol-based suspension. The base body can comprise a resin material. The resin material can, for example, be an armin resin, a phenolic resin, a polyester resin, a vinyl ester resin, a polyamide resin, an epoxy resin, an anhydride resin or a bismaleimide-triazine resin. The base body can, furthermore, comprise any combination of the above-mentioned resins.

It can be provided that the component, in other words both the base body and the coating comprising a ceramic material, is free of any electrically conductive material. Furthermore, the component can be free of any metallic materials and/or metallic alloys. In particular, the component can be produced so as to be free of any metallic adhesive medium. The component can thus be produced as a corrosion-free component.

Furthermore, it can be provided for the base body to be produced with fibres in crosswise layers. The fibres can be wound and/or laid in crosswise layers. For example, the crosswise layers can be produced with finishing circumferential layers.

The base body can comprise a fibre content of between 20 vol.-% and 80 vol.-%, between 20 vol.-% and 60 vol.-%, between 30 vol.-% and 60 vol.-% or between 30 vol.-% and 50 vol.-%. The fibres can comprise glass, carbon, ceramics, plastics and/or natural fibres. Glass fibres can, for example, comprise R-glass, E-glass, C-glass, D-glass or S-glass.

The characteristics described above in the context of the method analogously also apply to the component.

The element can be a rotationally symmetrical component, for example a roller comprising a cylindrical base body on which a coating comprising a ceramic material is directly arranged. The component can, for example, be an anilox roller or an anilox adapter or an anilox sleeve for flexographic printing, a treatment roller or a treatment adapter or a treatment sleeve for a corona treatment.

BRIEF DESCRIPTION OF THE DRAWINGS

Below, further embodiments are explained in more detail with reference to the figures of a drawing, which figures show the following:

FIG. 1 is a diagrammatic view of a roller;

FIG. 2 is a diagrammatic view of a further roller;

FIG. 3 is a diagrammatic view of another roller;

FIG. 4 is a diagrammatic view of a roller according to a further embodiment;

FIG. 5 is a diagrammatic view of a roller according to yet another embodiment;

FIG. 6 is a diagrammatic view of a component,;

FIG. 7 is a diagrammatic view of a further component; and

FIG. 8 is a diagrammatic view of a sleeve or of an adapter.

Below, the same reference characters have been used for identical components.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1 shows a diagrammatic view of a roller comprising a tubular substrate 1, a coating comprising a fibre-reinforced material 2 and a coating of a ceramic material 3. Studs 4 are arranged on both ends of the roller. The substrate 1 can, for example, comprise steel or aluminium. The coating comprising a fibre-reinforced material 2 is used as an insulation barrier. Said coating can comprise various types of fibres, for example glass fibres, carbon fibres, ceramic fibres, plastic fibres and/or natural fibres. The fibres have been embedded in an armin resin and have been applied to the tubular substrate 1 in wound crosswise layers. The coating of a ceramic material 3 has been applied directly to the fibre-reinforced coating 2. The ceramic coating 3 provides heat insulation. In this embodiment an oxide ceramic material has been provided as a ceramic material.

FIG. 2 shows a further embodiment of a roller. In this embodiment the tubular substrate 1 is shortened so that the intermediate region 5 is formed between the ends of the substrate 1 and the studs 4.

FIG. 3 shows a roller comprising a continuous tubular substrate 1.

FIG. 4 shows a roller comprising a fibre-reinforced coating 2 on which a ceramic coating 3 is directly arranged. The fibre-reinforced coating has been applied to a substrate 6 comprising a solid material, for example comprising steel or aluminium.

FIG. 5 shows a roller comprising a shortened tubular substrate 1, a fibre-reinforced coating 2 and a ceramic coating 3. On both ends of the roller a receiving device 7 is formed.

FIGS. 6 and 7 show diagrammatic illustrations of components of any desired shape. In each case a coating of a ceramic material 8, for example an oxide ceramic material, is directly arranged on a fibre-reinforced base body 9. According to the embodiment according to FIG. 7 the fibre-reinforced base body 9 is arranged on a substrate 10.

FIG. 8 shows a diagrammatic view of an adapter or of a sleeve. A coating of a ceramic material 23, for example an oxide ceramic material, is directly arranged on a fibre-reinforced base sleeve 20 comprising a compressible intermediate coating 21 and a fibre-reinforced base body 22 built-up directly on said intermediate coating 21. In this embodiment an intermediate coating 21 is arranged between the fibre-reinforced base body 22 and the fibre-reinforced base sleeve 20, which intermediate coating 21 comprises a compressible covering material.

The characteristics disclosed in the above description, in the claims and in the figures can be relevant both individually and in any desired combination in the context of implementation of the invention. 

1. A method for producing a coated component, comprising: providing a base body of a fibre-reinforced plastic, and applying a coating of a ceramic material directly to the base body.
 2. The method according to claim 1, wherein the coating comprising a ceramic material is applied to the base body by means of thermal spraying.
 3. The method according to claim 1, wherein the coating of a ceramic material comprises an oxide ceramic material.
 4. The method according to claim 1, wherein the coating of a ceramic material is applied in powder form to the base body.
 5. The method according claim 1, wherein the coating comprising a ceramic material is applied in one of a single layer and in multiple layers to the base body.
 6. The method according to claim 1, wherein the base body comprises a glass-fibre-reinforced plastic.
 7. The method according to claim 1, wherein the base body comprises a resin material.
 8. The method according to claim 1, wherein the base body comprises fibres wound in crosswise layers.
 9. The method according to claim 1, wherein the base body comprises a fibre content of between 20 vol.-% and 80 vol.-%.
 10. A coated component comprising; a base body made of a fibre-reinforced plastic; and a coating of a ceramic material arranged directly on the base body. 